Stihl FC 75 Bedienungsanleitung

STIHL Components4137

FC, FH, FS, HL, KM, KW 2004-06

STIH)

FC 75, FC 85

FH 75

FS 75, FS 80, FS 85

HL 75

KM 85

KW 85

SP 81

1FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85

Contents

1. Introduction 2

2. Safety Precautions 3

3. Specifications 4

3.1 Fuel System 4

3.2 Tightening Torques 5

4. Troubleshooting 8

4.1 Clutch 8

4.2 Rewind Starter 9

4.3 Fuel System 10

4.4 Engine 12

5. Engine 13

5.1 Shroud 13

5.2 Clutch 13

5.2.1 Removing and

Installing 13

5.2.2 Clutch Drum 15

5.3 Muffler/Spark Arresting

Screen 16

5.4 Removing and Installing

the Engine 17

6. Rewind Starter 17

6.1 General 17

6.2 Removing and

Installing 18

6.3 Rope Rotor/Rewind

Spring 19

6.3.1 Tensioning 20

6.4 Starter Rope 21

6.5 Starter Grip 21

6.6 Carrier/Pawl 22

7. AV System 23

7.1 Repair 23

8. Throttle Control 26

8.1 Control Handle on Loop

Handle up to 1997 26

8.1.1 Throttle Trigger /

Interlock Lever 26

8.1.2 Detent/Torsion Spring 27

8.1.3 Throttle Cable 28

8.2 Control Handle

up to 2002 28

8.2.1 Throttle Trigger/Interlock

Lever 28

8.2.2 Slide Control 29

8.2.3 Throttle Cable 30

8.3 Control Handle

from 2002 31

8.3.1 Throttle Trigger/Interlock

Lever 31

8.3.2 Contact/Detent Spring 32

8.3.3 Throttle Cable 33

8.4 Adjusting the Throttle

Cable 33

8.5 Control Handle on Bike

Handle up to 1997 34

8.5.1 Throttle Trigger/Interlock

Lever 34

8.5.2 Contact / Detent

Spring 35

8.5.3 Throttle Cable 36

8.6 Control Handle on Bike

Handle up to 2002 37

8.6.1 Throttle Trigger/Interlock

Lever 37

8.6.2 Contact / Detent

Spring 38

8.6.3 Throttle Cable 38

8.7 Control Handle on Bike

Handle from 2002 40

8.7.1 Throttle Trigger/Interlock

Lever 40

8.7.2 Contact/Detent Spring 41

8.8 Adjusting the Throttle

Cable 42

9. Fuel System 42

9.1 Air Filter 42

9.2 Carburetor 43

9.2.1 Leakage Test 43

9.2.2 Removing and

Installing 44

9.2.3 Spacer Flange 45

9.3 Servicing the

Carburetor 46

9.3.1 Flange Mounting

with Oval End Cover 46

9.3.2 Flange Mounting with

Square End Cover 47

9.3.3 Metering Diaphragm 47

9.3.4 Inlet Needle 48

9.3.5 Fixed Jet 48

9.3.6 Pump Diaphragm 49

9.4 Adjusting the

Carburetor 49

9.4.1 Carburetor with Two

Adjusting Screws 49

9.4.2 Carburetor with

LD Screw 50

9.4.3 User Adjustment,

Carburetor with

Limiter Cap 51

9.4.4 Service Adjustment,

Carburetor with

Limiter Cap 52

9.5 Tank Vent 54

9.6 Pickup Body 55

9.7 Fuel Tank/

Fuel Hoses 55

10. Drive Tube 57

10.1 Bike Handle 57

10.2 Loop Handle 57

10.2.1 Loop Handle with

Barrier Bar 57

10.2.2 Loop Handle without

Barrier Bar 58

10.2.3 Loop Handle with

Handle Hose 58

10.3 Drive Shaft/Flexible

Liner 59

10.3.1 Drive Shaft in Upper

End of Drive Tube

(KM 85 only) 60

10.4 Drive Tube 62

10.4.1 FS 80, 85, FH 75,

HL 75 62

10.4.2 Split Drive Tube

(KM 85 only) 63

10.5 Bearing Housing

(FS 75 only) 64

11. Special Sevicing

Tools 66

12. Servicing Aids 67

2FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85

This service manual contains

detailed descriptions of all typical

repair and servicing procedures for

models FC 75, 85, FH 75,

FS 75, 80, 85, HL 75, KM 85 and

KW 85, which are based on the

series 4137 powerhead.

If there is no specific reference to

individual machines, the procedure

is the same for all machines. The

illustrations may differ depending on

the machine, but the methods used

and the sequence of operations are

identical.

You will find detailed descriptions of

procedures for servicing and

repairing engine components and

associated CombiTools in the

service manual for the “Series 4137

Powerhead“.

You should make use of the

illustrated parts lists while carrying

out repair work. They show the

installed positions of the individual

components and assemblies.

Refer to the latest edition of the

relevant parts list to check the part

numbers of any replacement parts.

A fault on the machine may have

several causes. To help locate the

fault, consult the chapter on

"Troubleshooting" in this manual

and the "STIHL Service Training

System" for all assemblies.

Refer to the "Technical Information"

bulletins for engineering changes

which have been introduced since

publication of this service manual.

Technical information bulletins also

supplement the parts list until a

revised edition is issued.

The special servicing tools

mentioned in the descriptions are

listed in the chapter "Special

Servicing Tools" of this manual.

Use the part numbers to identify the

tools in the "STIHL Special Tools”

manual. The manual lists all special

servicing tools currently available

from STIHL.

Symbols are included in the text and

pictures for greater clarity.

The meanings are as follows:

In the descriptions:

:= Action to be taken as

shown in the illustration

(above the text)

– = Action to be taken that is

not shown in the illustration

(above the text)

In the illustrations:

Pointer

Direction of movement

b4.2 Reference to another

chapter, i.e. chapter 4.2

in this example.

Service manuals and technical

information bulletins are intended

exclusively for the use of properly

equipped repair shops. They must

not be passed to third parties.

Servicing and repairs are made

considerably easier if the machine

is mounted on assembly stand (2)

5910 893 3100 with the aid of

clamping fixture (1) 5910 890 8800.

The powerhead can then be

swivelled to the best position for the

249RA!63

ongoing repair.

Always use original STIHL

replacement parts.

They can be identified by the

STIHL part number,

the STIH) logo and the

STIHL parts symbol (

This symbol may appear alone on

small parts.

1. Introduction

3FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85

If the engine is started up in the

course of repairs or maintenance

work, observe all local and country-

specific safety regulations as well

as the safety precautions and

warnings in the instruction manual.

Gasoline is an extremely flammable

fuel and can be explosive in certain

conditions.

Improper handling may result in

burns or other serious injuries.

Warning!

Do not bring any fire, flame, spark or

other source of heat near the fuel.

All work with fuel must be performed

outdoors only. Spilled fuel must be

wiped away immediately.

2. Safety Precautions

4FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85

3. Specifications

3.1 Fuel System Carburetor: Diaphragm carburetor

Carburetor leakage test at gauge

pressure: 80 kPa (0.8 bar)

Fuel mixture: Regular brand-name gasoline with

min. 90 RON and STIHL 50:1

two-stroke engine oil; see instruction

manual for further details

Rated idle speed: 2,800 rpm

Rated cut-off speed: 10,500 rpm

Operation of tank vent:

- at gauge pressure: 50 kPa (0.5 bar)

- under vacuum: 20 kPa (0.2 bar)

5FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85

3.2 Tightening Torques

DG and P (Plastoform) screws are used in polymer and light metal components. These screws form a

permanent thread when they are installed for the first time. They can be removed and installed as often as

necessary without impairing the strength of the screwed assembly, providing the specified tightening torque is

observed.

For this reason it is essential to use a torque wrench.

Fastener Thread size For component Torque Remarks

lbf.ft Nm

Screw IS-P4x16 Control handle/handle molding (outer/inner) 0.75 1.0 1)3)4)5)6)8)

Screw IS-M5x12 Control handle/clamp/drive tube 3.6 5.0 1)3)4)5)6)8)

Screw IS-M5x30 Control handle/handlebar/locknut with

washer (bike handle) 1.5 2.0 2)7)

Screw IS-P4x16 Control handle/handle molding (outer/inner)

(bike handle) 0.75 1.0 2)7)

Screw IS-P4x16 Control handle/handle molding (outer/inner)

(loop handled machine) 0.75 1.0 2)7)

Screw IS-M5x12 Control handle/clamp/right-hand screw

(loop handled machine) 3.6 5.0 2)7)

Screw IS-DG5x16 Loop handle 1.8 2.5 1)3)8)

Screw IS-M6x50 Loop handle/drive tube/nut 2.6 3.5 1)3)8)

Mutter M5 Filter housing/carburetor/flange/screw 3.0 4.0

Screw IS-B4.2x9.5 Spark arresting screen/muffler 0.75 1.0

Screw IS-M5x84 Gearbox housing, left/right 1.1 1.5 6)

Locknut M5 Gearbox housing, left/right

(locknut) 4.4 6.0 6)

Screw IS-M6x20 Gearbox housing/drive tube 7.5 10.0 4)6)

Screw IS-M5x25 Housing, fan side/starter side 7.0 9.5 1)2)3)5)7)8)

Screw IS-DG5x24 Gearbox housing/drive tube 6.6 9.0 2)7)

Screw IS-M5x10 Quadrant/gear housing 5.9 8.0 6)

Screw IS-M4x16 Guard plate/gearbox cover 2.6 3.5 6)

Screw IS-M5x16 Shroud/fan housing 2.6 3.5

Screw IS-M5x16 Shroud/starter cover/crankcase 2.6 3.5

Screw IS-M5x20 AV sleeve (clamp screw) 4.0 5.5

6FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85

Fastener Thread size For component Torque Remarks

lbf.ft Nm

Screw IS-DG5x12 AV sleeve/drive tube, location 0.37 0.5

Screw IS-DG5x60 Retainer/deflector/drive tub 1.5 2.0 8)

Screw IS-M6x35 Clamp/clamp block/clamp

(bike handle) 3.3 4.5 2)7)

Tommy screw M6x30 Coupling sleeve/tommy screw

(version with split boom) 4.4 6.0 2)7)

Screw IS-M6x25 Coupling sleeve/clamp nut

(version with split boom) 6.6 9 2)7)

M8 Clutch carrier/flywheel/

crankshaft 19.2 26.0

Screw IS-M5x16 Fan housing/crankcase 5.9 8.0

Screw IS-M6x25 Clamp/loop handle

(loop handled machine) 3.3 4.5 2)4)6)7)

Nut M5 DS270 mm blade/screw 7.0 9.5 6)

M8 Carrier 10.3 14.0

Collar nut P3.5x9.0 Detent spring/slide control/control handle 1.5 1.1 2)7)

Screw IS-M5x22 Clamp/drive tube/harness adjustment

(version with split boom) 2.2 3.0 2)7)

Screw IS-P5.5x12 Rope rotor/starter cover 2.6 3.5

Screw IS-5x33 Clamp/deflector 3.3 4.5 1)

Screw IS-5x16 Muffler/crankcase 7.0 9.5

Screw IS-5x16 Muffler/cylinder 8.5 11.5

Screw IS-M6x14 Clamp/drive tube/harness adjustment 3.3 4.5 2)5)7)

Screw IS-M5x18 Clamp/bearing housing/locknut

4.8 6.5 1)

Screw IS-M5x16 Starter cover/crankcase 4.0 5.5

Screw IS-M5x22 Carrying ring/clamp 2.2 3.0 4)6)

Screw IS-M5x25 Spacer flange/cylinder (with washer) 4.0 5.5

Screw IS-DG5x24 Cylinder/crankcase 7.0 9.5

Spark plug M14x1.25 Spark plug 15.0 20.0

Screw IS-M4x20 Ignition module/cylinder (with washer) 3.3 4.5

Screw IS-M5x25 Spacer flange/cylinder (with washer) 4.0 5.5

7FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85

Remarks:

1) FS 75

2) FS 80, 85

3) FC 75

4) HL 75

5) KW 85

6) FH 75

7) KM 85

8) FC 85

Use the following procedure when refitting a DG or P screw in an existing thread:

Place the screw in the hole and rotate it counterclockwise until it drops down slightly.

Tighten the screw clockwise to the specified torque.

This procedure ensures that the screw engages properly in the existing thread and does not form a new thread

and weaken the assembly.

Power screwdriver settings for polymer:

Plastoform screws: max. 600 rpm

DG screws: max. 500 rpm

Important:

Do not mix up screws with and without binding head

8FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85

4. Troubleshooting

4.1 Clutch

Condition Cause Remedy

Tool stops at full throttle

under load

Clutch shoes badly worn Install new clutch shoes or a new

clutch

Clutch drum badly worn Replace clutch drum

Tool runs at idle speed Idle speed too high Readjust idle speed screw

(counterclockwise)

Clutch springs stretched or

fatigued

Fit new clutch springs

Clutch spring hooks broken Fit new clutch springs

Loud noises Clutch springs stretched or fatigued Replace all clutch springs

Clutch shoe retainer (carrier)

broken

Fit new retainer (carrier) or clutch

Clutch shoes and carrier worn Install a new clutch

Needle cage damaged Install a new needle cage

9FC 75, FC 85, FH 75, FS 75, FS 80, FS 85, HL 75, KM 85, KW 85

4.2 Rewind Starter

Condition Cause Remedy

Starter rope broken Rope pulled out too vigorously as

far as stop or over edge, i.e. not

vertically

Fit new starter rope

Normal wear Fit new starter rope

Rewind spring broken (starter rope

does not rewind)

Spring overtensioned – no reserve

when rope is fully extended

Fit new rewind spring

Very dirty or corroded Clean rewind spring or install new

spring

Starter rope can be pulled out

almost without resistance

(crankshaft does not turn)

Guide peg on pawl or pawl itself

is worn

Fit new pawl

Spring clip fatigued Fit new spring clip

Starter rope is difficult to pull and

rewinds very slowly

Starter mechanism very dirty

(dusty conditions)

Thoroughly clean complete starter

mechanism

Lubricating oil on rewind spring

becomes viscous at very low

outside temperatures (spring

windings stick together)

Coat rewind spring with a standard

solvent-based degreasant

(containing no chlorinated or

halogenated hydrocarbons). Then

pull rope carefully several times

until normal action is restored

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